Diaper cloth and no-fold panel diaper



nmlvmun July 11, 1961 J. 1.. SULLIVAN DIAPER CLOTH AND NO-FOLD PANELDIAPER Filed April 6, 1959 2 Sheets-Sheet 1 FIG. l.

a T- r' 1:; r Wi li 7 E VENTOR 2 JOHN L. SULLIVAN ATTORNEYS July 11,1961 J. SULLIVAN DIAPER CLOTH AND NO-FOLD PANEL DIAPER Filed April 6.1959 2 Sheets-Sheet 2 INVENTOR JOHN L. SULLIVAN ATTORNEYS United StatesPatent Ofitice 2,991,786 Patented July 11, 1961 2,991,786 DIAPER CLOTHAND N O-FOLD PANEL DIAPER John L. Sullivan, Scotch Plains, N.J.,assignor to Georgian Baby Products Co., Inc., New York, N.Y., acorporation of New York Filed Apr. 6, 1959, Ser. No. 804,536

3 Claims. (Cl. 128284) This invention relates to cloth particularlyintended for use as diapers; to a no-fold panel diaper made therefrom;and this application is a continuation-in-part of my application SerialNo. 718,682 filed March 3, 1958, now abandoned.

Heretofore various diaper constructions have been proposed but most ofthese sufier from one or more of the disadvantages of requiring foldingbefore application to the baby; lack of absorptive power; and excessivebulkiness for the intended use.

By the present invention I have, for the first time, provided a novelcloth suitable for the making of a nofold panel diaper which requires nofolding before application to the baby; which has absorptive capacitiesin excess of 300% against the dry weight thereof; and which is not bulkyand is easily applied to and comfortable on the baby. 7

The 'novel cloth of the present invention and the nofold panel diapermade therefrom are capable of various mechanical embodiments two ofwhich are shown in the accompanying drawings to illustrate the presentinvention. These illustrative embodiments of the present inventionshould in no way be construed as defining or limiting the same andreference should be had to the appended claims to determine the scope ofthe present inventive concept.

In the accompanying drawings, in which like reference charactersindicate like parts, FIG. 1 is a view of a finished no-fold panel diaperin accordance with an embodiment of the present invention;

FIG. 2 is a cross sectional view on the line 22 of the embodiment ofFIG. 1;

FIG. 3 is a view of the cloth of the present invention from which thediaper of FIGS. 1 and 2 was made; and

FIG. 4 is a view of another embodiment of the present invention.

Referring now more particularly to FIG. 3, it will there be seen thatthe diaper cloth of the present concept shown generally at includes aleft panel section 11, 12, 21, 22, having a selvedge edge 23 and is ofany suitable weave such as birds-eye weave. Woven integrally with panel11, 12, 21, 22 along line 12, 21 is tubular panel 27, 28 which is wovenby a high harness dobby loom and panel 27, 28, is of suitable weave, andis formed of more absorptive thread than is panel 11, 12, 21, 22.

Woven integrally with tubular panel 27, 28 along line 13, 20 is panel13, 14, 19, 20 of suitable width and of similar weight and weave topanel 11, 12, 21, 22. A second tubular panel 29, 30 is woven integrallywith panel 13, 14, 19, 20 along line 14, 19 and is similar to tubularpanel 27, 28 both in weave and in width. A right panel 15, 16, 17, 18 iswoven integrally with tubular panel 29, 30 along line 15, 18 and isidentical with panel 11, 12, 21, 22 both in weave and weight and isfinished with a selvedge edge 24.

In forming the no-fold panel diaper of FIG. 1 the cloth described withrespect to FIG. 3 is cut to suitable length across the warp and is thenfolded along center line 25, 26 to bring selvedge edges 23 and 24 intocoincidence. Straight seams are then formed along the lines 25, 11 and25, 16 and along lines 26, 22 and 26, 17 to form a bag open at theselvedge edges 23 and 24. The selvedge edges 23 and 24 are sewn togetherforming the no-fold panel diaper of FIG. 1.

A suitable diaper in accordance with FIG. 1 is 14 /2 inches wide and 21/2 inches long. To form such a diaper panel 11, 12, 21, 22 and panel 15,16, 17, 18 should be 4 inches wide; panel 13, 14, 19, 20 should be 8inches wide; and tubular panels 27, 28 and 2.9, 30 should be 7V2 incheswide. Although these dimensions are used in the present concept it isunderstood that these dimensions should be adaptable to conform to thesize of the user.

If a coarse yarn dobby weave is employed, panels 11, 12, 21 and 22 and15, 16, 17 and 18 may have from fifty to seventy ends of 14/1 to 2.4/1cotton in the warp and thirty-six to fifty picks of 10/1 to 17.25/1cotton soft twist filling. Tubular panels 27, 28 and 29, 30 may havetwenty-five to thirty-five ends of 4/1 to 6/ 1 cotton in the warp andeighteen to twenty-five picks of 10/ 1 to 17.25/1 cotton soft twistfilling per side of tube or panel. The yarn twist multiplier in bothwarp and filling should be between 3.00 and 3.75. Panel 13, 14, 19, 20,as pointed out above, is of the same weave and weight as panels 11, 12,21, 22 and 15, 16, 17, 18. The diaper formed of coarse yarn dobby clothof this weight and weave has absorptive capacities in excess of 300%against its dry weight as proved by impartial tests of a commercialtesting company.

In a specific embodiment of the cloth described above a'birds-eye weavewas employed having sixty ends of 20/1 cotton in warp and forty picks of10/1 soft twist cotton filling in the edge and central panels and thetubular panels had thirty ends of 4/1 cotton in the warp and twentypicks of 10/1 soft twist cotton filling per side.

In the embodiment of FIG. 4 side panel 11, 12, 21, 22 with its selvedgeedge 23 is woven as above described for the embodiment of FIGS. l-3. Inthis embodiment, however, tubular panel 27, 28, woven as abovedescribed, is provided with an integral center ply 31 to provide atriple layer absorptive center panel for the diaper. Central panel 13,14, 19, 20 is woven as above described for the embodiment of FIGS. 1-3but a medial cutting strip 32 is provided between panel 13, 25, 2.6, 20and the next adjacent panel 25, 14, 19, 26 so that as many diapers canbe woven as the width of the loom will accommodate, the diapers beingsubsequently separated along the cutting strips and cut to suitablelength across the warp. While FIG. 4 shows two diapers across the widthof the material it is to be understood that any convenient number may bewoven as a unit and then separated as above described.

The diaper of the embodiment of FIG. 4 requires no folding andsubsequent sewing along overlayed selvedge edges as in the embodiment ofFIGS. 1-3. The triple layer center panel exhibits unexpected absorptivecapacity when the cloth is a coarse yarn dobby weave in which panels 11,12, 21, 22 and 13, 25, 26, 20 may have from 5658 warp ends and from40-54 filling picks; in which the triple center panel 27, 28, 31 mayhave from 28-36 warp ends in each and panels 27 and 28 may have from1622 picks and ply 31 may have from 8-l0 picks. The yarn sizes in theside panels may range from 14/1-24/1 cotton in the warp and 10/1-l7.25/1soft twist cot-ton filling while the yarn sizes in the triple centerpanel 27, 28, 31 may range from 4/1-8/1 soft twist cotton in the warpand 10/l17.25/1 soft twist cotton filling.

A specific construction of the embodiment of FIG. 4 having unexpectedabsorptive qualities has in the side panels 46 ends of 20/1 cotton and48 picks of 10/1 soft twist cotton and in panels 27 and 28 32 ends of 6/1 soft twist cotton and 19 picks of 10/1 soft twist cotton while layer31 has 32 ends of 6/1 soft twist cotton and 10 picks of 10/1 soft twistcotton.

For the embodiment of FIG. 4 the yarn twist multiplier for all yarns isfrom 3.00 to 3.75.

It should now be apparent that the present invention in every waysatisfies the several objectives discussed above by providing a highlyabsorptive no-fold diaper which need not be folded before application tothe baby and which is not bulky and uncomfortable for the baby.

Changes in or modifications to the above described illustrativeembodiment of this invention may now be suggested to those skilled inthe art without departing from the present inventive concept. Referenceshould therefore be had to the appended claims to determine the scope ofthis invention.

What is claimed is:

1. A no-fold diaper comprising side panels of coarse yarn dobby weave,an intervening highly absorptive central tubular panel having at leastthree layers woven integrally with said side panels, at least a portionof each of the side panels at least at one end thereof being of widthsubstantially one-half of that of the central panel, said side panelshaving approximately fifty eight to sixty-eight ends of 14/1 to 24/1cotton in the warp and approximately forty to fifty-four picks of /1 to17.25/1 cotton soft twist filling, each of the layers of said tubularpanel having approximately twenty eight to thirty-six ends of 4/ 1 to8/1 cotton in the warp and approximately eight to twenty-two picks oflO/l to 17.25/1 cotton soft twist filling woven integrally with saidside panels, the picks of the side panels being divided among the threelayers of the central panel in such proportion that the number of picksin each outer layer of the central panel substantially exceeds thenumber of picks in the intermediate layer, whereby the'tubular panel issufliciently porous to pass gases and provides surface flexibility andmaximum absorptive capacity, each of the end edges of the layers formingthe tubular central panel being secured together respectively.

2. The combination set forth in claim 1 in which each of said sidepanels has sixty-four ends of 20/1 cotton and forty-eight picks of 10/1soft twist cotton, each of the two outer layers of said tubular panelhas thirty-two ends of 6/ l cotton and nineteen picks of 10/1 soft twistcotton and the intermediate layer of said tubular panel has thirty-twoends of 6/1 cotton and ten picks of 10/1 soft twist cotton.

3. The combination set forth in claim 1 in which the width of each ofthe side panels along its entire length is substantially one-half thewidth of the central panel.

References Cited in the file of this patent UNITED STATES PATENTS776,087 Robitschek Nov. 29, 1904 2,161,539 Swartz June 6, 1939 2,713,359Dangel et al. July 19, 1955 2,845,069 Jamison et al. July 29, 1958FOREIGN PATENTS 23,028 Great Britain June 3, 1915 365,974 Great BritainJan. 28, 1932 UNITED STATES PATENTOFFICE CERTIFICATE OF CORRECTIONPatent No...2 -99l ,786 7 July 11 1961 John L. Sullivan It is herebycertified that error appears in the above numbered patent requiringcorrection and that the said Letters Patent should read as correctedbelow.

Column 2,, line 56 for "56-58" read 58-68 line 67! V for "46, read 64Signed and sealed this 3rd day of April 1962,

(SEAL) I Attest:

ERNEST W. SWIDER DAVID L. LADD Attesting Officer Commissioner of Patents

